Polarized lens and method of making polarized lens

ABSTRACT

Method of making eyeglass lens are disclosed where the lens are made of layers which include an outer, convex hard coating, a layer of hard epoxy, a laminated PVA film where one of the layer of the PVA film is dipped in high contrast dye, a layer of soft epoxy, a base material, and an inner, concave hard coating. Other methods configuration of lens also include a camouflaged patterned lens, a layer of hard epoxy, a polyurethane mixture, a laminated PVA film where one of the layer of the PVA film is dipped with high contrast dye, a layer of soft epoxy, a base material, and an inner, concave hard coating.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation In Part (CIP) of U.S. utility patentapplication Ser. No. 12/244,760 filed on Oct. 2, 2008 now abandoned,which is a Continuation In Part (CIP) of U.S. utility patent applicationSer. No. 12/281,379 filed on Sep. 2, 2008 now U.S. Pat. No. 7,927,522which claims the benefit of the filing date of PCT patent applicationSer. No. PCT/US07/22710, filed on Oct. 25, 2007, the disclosures ofwhich are incorporated herein by reference.

FIELD OF THE INVENTION

This invention is generally related to eyewear, and more particularly topolarized lenses for glasses and a method of making polarized lenses.

BACKGROUND OF THE INVENTION

Polarized lenses have been made using wafers of flat, laminated layersincluding polarized films, such as polyvinyl alcohol (PVA), laminatedwith polymers, such as CR-39 or polyurethane, which are subjected toheat and pressure and then bent into the desired lens curvature. Suchwafers are not strong, and the heating and bending of the polarized filmwith its composite sheets in a mold or casting could result insplitting, cracking, or optical deformation. Injection molding at lowertemperatures could damage the surface of the polymer, while use of hightemperatures could damage the surface of the polarized film. It could bedifficult to obtain the desired radius of curvature without damaging thealready laminated wafer.

Such lenses did not take advantage of the polarizing qualities ofpolyvinyl alcohol (PVA) combined with the use of quantities of epoxywhich can include photochromic agents. Such lenses also did not allowfor the polymer base material and the polarized film to be separatelydipped for coloring. Such lenses were not always suitable for readingglasses, goggles, prescription RX lens, or sunglasses with polarizedphotochromic, colored, or gradient lenses.

It is therefore an object of the invention to provide a method of makingpolarized lenses, which avoids the problems associated with currentmethod of preparing lenses, and to provide a lens made by said method.

SUMMARY OF THE INVENTION

An eyeglass lens is made of layers which include an outer, convex hardcoating, a layer of hard epoxy, a PVA film, a layer of soft epoxy, alayer of adhesive, a base material, and an inner, concave hard coating.The major steps in producing the lens are to 1: prepare a clean, softPVA film; 2: form the PVA film into the desired curved shape using aconvex mold; 3: add hard epoxy to the outer, convex side of the PVAfilm; 4: add soft epoxy to the inner, concave side; 5: add the basematerial to the inner, concave side; and 6: harden and package the lens.

In one embodiment, a method of making a polarized lens comprising thesteps of: progressively wetting, stretching, dyeing, cleaning a firstpolyvinyl alcohol (PVA) film by an assembly line having rollers so as tolet molecules of the first PVA film have a parallel lineal direction;providing a first holder having a lower frame and an upper frame coupledby a hinge; clipping the first PVA film with a first surface thereofdownward in the first holder, so that both of the upper frame and thelower frame with two opposite plates clip the first PVA film along adirection perpendicular to the parallel direction of molecules in orderto prevent the first PVA film itself from shrinking; pressing a firstconvex mold against the first surface of the first PVA film through anopening of the lower frame of the holder, thereby substantiallyconforming the first PVA film to the first convex mold, and the firstsurface becoming a concave surface and a second surface opposite thefirst surface becoming a convex surface; pressing a concave mold againstthe second surface of the first PVA film, thereby substantiallyconforming the first PVA film to the concave mold; drying the first PVAfilm; remove the first convex mold; progressively wetting, stretching,dyeing, cleaning a second polyvinyl alcohol (PVA) film by an assemblyline having rollers so as to let molecules of the second PVA film have aparallel lineal direction; providing a second holder having a lowerframe and an upper frame coupled by a hinge; clipping the second PVAfilm with a first surface thereof downward in the second holder, so thatboth of the upper frame and the lower frame with two opposite platesclip the second PVA film along a direction perpendicular to the paralleldirection of molecules in order to prevent the second PVA film itselffrom shrinking; pressing a second convex mold against the first surfaceof the second PVA film through an opening of the lower frame of theholder, thereby substantially conforming the second PVA film to thesecond convex mold, and the first surface becoming a concave surface anda second surface opposite the first surface becoming a convex surface;drying the second PVA film; applying a quantity of glue on the center ofthe first surface of the first PVA film; up-side down pressing thesecond convex mold having the second surface of the second PVA filmagainst the glue so as to form a laminated PVA film by spreading theglue in a circular motion; hardening the laminated PVA film; andremoving the concave mold.

The embodiment further comprising applying a quantity of first epoxy onthe center of an upper surface of the concave mold; up-side downpressing the second convex mold having the convex surface of thelaminated PVA film against the first epoxy so as to form a laminatedfirst epoxy film by spreading the first epoxy in a circular motion;hardening the laminated first epoxy film; and removing the concave mold.

One embodiment further comprises applying a quantity of firstpolyurethane (PU) mixture on the center of an upper surface of theconcave mold; up-side down pressing the second convex mold having thesecond surface of the laminated PVA film against the first PU mixture soas to form a laminated first PU film by spreading the first PU mixturein a circular motion; hardening the laminated first PU film; andremoving the concave mold.

In one embodiment, the step of progressively wetting, stretching,dyeing, cleaning the first and second PVA film, comprising the steps ofproviding a roll of PVA film; providing an assembly line having rollers;mounting the roll of PVA film at the beginning of the assembly line;using water to wet the PVA film at a first stage of the assembly lineuntil it has moisture content between 70% and 85%; stretching the PVAfilm at a second stage of the assembly line; and dye-dipping the PVAfilm at a third stage of the assembly line until the PVA filmsubstantially polarized.

In another embodiment, each stage have at least one bath and each bathhaving rollers placed at a lower position closed to the bottom androllers placed at a higher position and from a bath to another alsohaving rollers placed atop sidewalls between two adjacent baths so thatthe PVA film can be stretched continuously. And can further include thesteps of: stabilizing the PVA film; and cutting the PVA film.

In one aspect, the base material comprises: at least one materialselected from the group of polycarbonate, polyurethane, nylon, CR-39,glass, Acrylic. In another aspect, the base material is combined withthe laminated second epoxy film using glue or cell casting or insertinjection molding. Likewise, the base material can further compriseglued pre-formed anti-fog layer.

The glue disclosed here can be epoxy or polyurethane. In one embodiment,the first PVA film is dipped in a tank containing high contrast dyewherein the first PVA film is clipped by a frame or frame with mold,rotating the frame or frame with mold slowly and continuously.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is generally shown by way of reference to the accompanyingdrawings in which:

FIG. 1 depicts one embodiment of a lens having layers;

FIG. 2 depicts one embodiment of an assembly line to prepare a clean,soft PVA film;

FIGS. 3A and 3B depict one embodiment of a holding frame;

FIGS. 4A and 4B depict one embodiment of the PVA film being formed intothe desired curved shape using one side of a convex mold;

FIGS. 5A and 5B depict one embodiment of a thin, outer layer of epoxybeing added to the PVA film;

FIG. 6 depicts an embodiment of a compressor with UV hardeningequipment;

FIG. 7 depicts one embodiment of soft epoxy being added to form a buffergel layer on the inner, concave surface; and

FIG. 8 depicts the base material of the lens being glued to the inner,concave surface.

FIG. 9 depicts one embodiment of the cross-sectional view of a layeredlens produced by the present claimed methods.

FIG. 10 depicts one embodiment of the cross-sectional view of a layeredlens produced by the present claimed methods.

FIG. 11 depicts one embodiment of the cross-sectional view of a layeredlens produced by the present claimed methods.

FIG. 12 depicts one embodiment of the cross-sectional view of a layeredlens produced by the present claimed methods.

FIG. 13 depicts one embodiment of the cross-sectional view of a layeredlens produced by the present claimed methods.

FIG. 14 depicts the dipping of the first PVA film in a tank containingcolor.

DETAILED DESCRIPTION OF THE INVENTION

Some embodiments are described in detail with reference to the relateddrawings. Additional embodiments, features and/or advantages will becomeapparent from the ensuing description or may be learned by practicingthe invention. In the figures, which are not drawn to scale, likenumerals refer to like features throughout the description. Thefollowing description is not to be taken in a limiting sense, but ismade merely for the purpose of describing the general principles of theinvention. The steps described herein for performing methods form oneembodiment of the invention, and, unless otherwise indicated, not all ofthe steps must necessarily be performed to practice the invention, normust the steps necessarily be performed in the order listed.

The present invention is a polarized lens and a method of makingpolarized lenses. As depicted in FIG. 1, one embodiment of lens 10 willhave layers as follows: outer, convex hard coating 12; layer of hardepoxy 14; PVA film 16; layer of soft epoxy 18; layer of adhesive 20;base material 22; and inner, concave hard coating 24. A “convex” surfacegenerally bulges out like the outside of a ball, and a “concave” surfacegenerally curves in like the inside of a bowl. The lens user or eyeglasswearer generally peers into the concave side, so the concave side oflens 10 is “inner” and the convex side is “outer.” In anotherembodiment, layer of adhesive 20 and base material 22 are above PVA film16, rather than below it as depicted in FIG. 1, resulting in a lens 10where base material 22 is closer to the outer side than the inner side.

PVA 16 is polarized polyvinyl alcohol and may also be tinted or combinedwith a photochromic agent, which is a chemical that causes a reversiblechange in color or darkness on exposure to light. Adhesive 20 could bemade of a mixture of acrylic resin, polyurethane and oil based solvent.Base material 22 could be polycarbonate, polyurethane, polyethylene,nylon, allyl diglycol carbonate monomer (CR-39), Polymethyl-methacrylate(PMMA), glass, or other material, and can be injection molded orotherwise cast with or without pressure to have a desired curvature andoptical qualities. Base material 22 could be pre-formed with hardcoatings on one or both sides. Outer, convex hard coating 12 and inner,concave hard coating 24 can be resin materials that provide scratchresistance, UV protection, anti-reflective coatings, mirrored coatings,multi-layer coatings, water-resistance, decorative designs, or acombination of these features. The coatings on the lens or base materialcan be applied by deposition or vacuum coating, and can include amirrored coating on the outer, convex side, or an anti-reflectivecoating on the inner, concave side.

Hard epoxy 14 is “hard” because it is near the outer surface of the lenswhere scratch resistance is desirable, and soft epoxy 18 is “soft”because it acts as a buffering gel between PVA 16 and base material 22to help prevent cracking. Both can be any epoxy or epoxy mixture, andcan consist of more than half epoxy resin combined with one or more ofpolyurethane, acrylic resin, CR-39, or silicon. Both can also be mixedwith coloring, tinting, photochromic agents, infrared or ultravioletblockers, stabilizers, stiffeners, anti-oxidants, anti-fog treatments,or silicon hard coatings. In one embodiment, hard epoxy 14 has a pencilsoftness rating of 1B to 3B, and soft epoxy 18 has a pencil softnessrating of 2B to 4B.

The major steps in producing the lens are described in the followingsections.

1. Prepare a Clean Soft PVA Film

FIG. 2 depicts one embodiment of an assembly line to prepare a clean,soft PVA film. Start with an untreated roll of PVA film 102, which isabout 0.075 mm thick and generally without sufficient sunlight glareprotection or directional molecular arrangement (generally notpolarized). Process using assembly line 100 which has rollers totransport PVA film 102 through one or more stages as follows:

-   -   mount untreated roll of PVA film 102 at the beginning of        assembly line 100;    -   use water to wet, clean, and wash the film until it has        approximately 70%-85% water saturation in stage 104;    -   soften, expand and stretch the film in stage 106;    -   dye dip the film to add tinting, color, or photochromic agents,        and further stretch the film in stage 108; and    -   clean the film again in stage 110.

PVA film 102 is stretched to about 4 to 6 times its original length, itswidth is reduced to about one half its original width, and its thicknessis reduced to about one third of the original thickness, namely, about0.02 mm to 0.03 mm. The molecules of PVA film 102 will become moreevenly aligned and will become substantially polarized, which reducesglare. Darker lenses, such as those which transmit only 13% to 18% ofthe light, should filter out approximately 95% to 99% of unpolarizedlight. Lighter lenses, such as yellow lenses, would filter less than95%. PVA film 102 is placed in water until it contains about 70%-85%water, which will make it soft and elastic. PVA film 102 can be dippedto produce either a uniform coating or a gradient effect usingphotochromic agents or coloring chemicals such as dichroic dyes oriodine. This produces a clean, polarized PVA film 112 which is soft dueto its high water saturation, which can be fed into a second assemblyline for further processing.

2. Form the PVA Film into the Desired Curved Shape Using a Convex Mold

FIGS. 3A and 3B depict one embodiment of a holding frame 114. PVA film122 is stabilized between lower frame plate 116 and upper frame plate118, which are held together with frame hinge 120 and clip 122.Additional clips can be used to help prevent PVA film 112 from shrinkingduring shaping.

FIGS. 4A and 4B depict one embodiment of the PVA film being formed intothe desired curved shape using one side of a convex mold as follows:

-   -   stabilize and cut PVA film 112 on holding frame 114;    -   press convex mold 124 onto PVA film 112 to force the film into        the desired curved shape;    -   heat PVA film 112 at 60° C. to 80° C. until its moisture content        is about 50%;    -   inspect and mark the polarization direction of PVA film 112; and    -   dry the PVA film 112 at approximately 25° C. and 40-50% humidity        until its moisture content is about 40%.

PVA film 112 is cut from the end of the clean, soft PVA film output fromassembly line 100 into the approximate final lens size or larger.Holding frame 114 is open in the center, which allows convex mold 124 tobe pushed through holding frame 114 and against PVA film 112. FIG. 3Bshows that holding frame 114 can be held on a conveyor belt which isused in the second assembly line.

One side of convex mold 124 is used to shape PVA film 112. The convexsurface of convex mold 124 is pushed into the flat piece of soft film tobend it into the desired shape, curve or arc. Since PVA film 112 is softand wet, it will conform its shape to the mold. In one embodiment,convex mold 124 is made of glass, such as glass in common practice forforming thermoset resin ophthalmic lenses, or another material that isrelatively transparent or ultraviolet light, so that the epoxy can becured by UV light which passes through the mold. In other embodiments,convex mold 124 is made of a material which conducts heat, so that heatcan pass through the mold.

PVA film 112 is heated at about 80° C. or less to remove the moisturefrom the wet PVA without melting it. This should take about 10 minutes.PVA film 112 was “wet” because its moisture content made it relativelysoft, and it becomes “dry” because the reduction in moisture contentwill fix or lock in its shape. Temperatures above 80° C. may act to meltor liquefy the film.

PVA film 112 is inspected in a quality control stage after the initialdrying for air bubbles, dirt, color evenness, polarization levels,tears, etc. The diopter and other optical properties of PVA film 112 canbe measured. If all is approved, the lens is marked with a polarizationdirection marker. After marking, PVA film 112 can then be removed to aclean room at room temperature and low humidity levels for furthercooling until PVA film 112 contains about 40% water, which is a goodmoisture content to adhere with epoxy or other materials. Dryerconditions below 30% can cause cracking. This produces a curved, dry PVAfilm 112, which eventually becomes PVA film 16 layer in final lens 10.

3. Add Hard Epoxy to the Outer, Convex Side of the PVA Film

FIGS. 5A and 5B depict one embodiment of a thin, outer layer of epoxybeing added to the PVA film as follows:

-   -   polish and clean the surface of concave mold 130;    -   add about 5 cc of hard epoxy 132 in liquid form onto concave        mold 130; and    -   position concave mold 130 and convex mold 124 together so that        the outer surface of PVA film 122 is pressed down onto hard        epoxy 132;    -   compress molds 124 and 130 together;    -   determine direction of polarization; and    -   UV hardening.

Like convex mold 124, concave mold 130 can be made of transparent glass.About 5 cc of hard epoxy 132 is used, which should spread out to form alayer about 0.1 mm-0.5 mm thick, preferably 0.2 mm-0.3 mm for goodsurface tension. This eventually becomes layer of hard epoxy 14 in lens10. Thermosetting epoxies should be heated to about 80° C. to 90° C. sothat they will be liquid or semi-liquid, to help eliminate bubbles, andso that coloring, photochromic agents, UV and infrared-blocking powderscan be added. The liquid epoxy is soft enough to flow, but it is not soviscous that it will flow away without adhering. The liquid epoxy can bedripped onto PVA film 112, smoothly expanding from the center in acircular motion to evenly spread the epoxy and help remove air bubbles.This process can be performed in an environment at approximately roomtemperature.

In one embodiment, holding frame 114 still holds PVA film 112 in contactwith convex mold 124, and the convex mold-plus-PVA film combination isinverted and placed on top of concave mold 130 and attached togetherwith a mold-holding tool (not shown). Because the final layer of hardepoxy 132 is less than 0.5 mm, no gasket is needed. During UV hardening,the liquid epoxy is cured and made hard using ultraviolet light, heat,radiation, pressure, passage of time, or other methods for hardeningepoxy.

FIG. 6 depicts an embodiment of a compressor 140, which could be anadjustable compressing machine. The PVA-plus-epoxy collection of holdingframe 114, convex mold 124, PVA film 112, hard epoxy 132 and concavemold 130 are placed in compressor 140. The convex side of PVA 112 filmis pressed down against the epoxy-lined surface of concave mold 130 tohelp remove air bubbles and evenly spread out the layer of hard epoxy132. The pressure is applied by compressor 140 to adjust the thicknessof hard epoxy 132 to the desired thickness, which is about 0.1 mm to 0.2mm. The polarization is also be adjusted. In one embodiment, in additionto pressing, compressor 140 also performs preliminary UV hardening usingUV light source 142. In other embodiments, compressor 140 includesheating equipment or other equipment for curing epoxy or allowing epoxyto harden.

The PVA-plus-epoxy collection is then sent to an assembly line with UVhardening equipment to be hardened for about three minutes. Fine shapingcan also be performed manually at this stage by cutting away excess PVA.This produces a PVA film 112 with a hard layer of epoxy 132 on itsouter, convex surface.

In another embodiment, this produces a polarized wafer coated with epoxyon one side. The uncoated concave side, the epoxy-lined convex side, orboth sides could then be combined with a base material, through castingin a gasket mold, injection molding, or other methods for combining lenscomponents.

4. Add Soft Epoxy to the Inner, Concave Side

FIG. 7 depicts one embodiment of soft epoxy being added to form a buffergel layer on the inner, concave surface as follows:

-   -   remove holding frame 114 and cut away the excess PVA film 122;    -   remove convex mold 124;    -   inject about 5 cc of soft epoxy 150 in liquid form onto the        exposed, concave side of PVA film 112;    -   place convex mold 124 back on top so that the concave surface        presses against soft epoxy 150;    -   compress molds 124 and 130 together;    -   UV hardening; and    -   remove convex mold 124 again.

Excess PVA can be cut away manually, using a lens-cutting machine, orwith a computer numerical control (CNC) cutting machine, to form avariety of lens shapes. Compressor 140 is used again, and can alsoperform preliminary UV or other hardening of soft epoxy 150. Thisresults in a shaped PVA film 112 with epoxy on both sides. Soft epoxy150 eventually becomes layer of soft epoxy 18 in lens 10. Instead ofre-using convex mold 124, a third mold or another properly shapedcomponent could be used to press against soft epoxy 150.

In another embodiment, this produces a polarized wafer coated with epoxyon both sides. One or both sides of the polarized wafer could then becombined with a base material, through casting in a gasket mold,injection molding, or other methods for combining lens components.

5. Add the Base Material to the Inner, Concave Side

FIG. 8 depicts the base material of the lens being glued to the inner,concave surface as follows:

-   -   add about 2 cc of adhesive 152 onto the exposed, concave surface        of soft epoxy 150;    -   combine with base material 154;    -   compress mold 130 against base material 154; and    -   inspect.

Compressor 140 is used again, and can also perform preliminary UV orother hardening of adhesive 152. Base material 154 can have coatings oneither side, which can include hard coatings, multi-layer coatings,water resistance, reflector coatings or mirrored coatings, eitheruniform or in patterns or gradients. Adhesive 152 and base material 154will eventually become layer of adhesive 20 and base material 22 of lens10. The combined lens is inspected to check for optical functionality,dirt, adhesion conditions, etc. If it passes inspection, it is sent tothe next step; otherwise, the rejected lens is processed accordingly.

6. Harden and Package the Lens

The outer layers of the lens are hardened as follows:

-   -   sonic cleaning;    -   heat dry;    -   enter a clean laboratory;    -   perform single-sided lens hardening;    -   check for defects, remove any remains and excess PVA, clean, and        inspect again;    -   perform single-sided lens hardening on the other side; and    -   package the finished lens.

The hardening applied to the convex surface will become convex hardcoating 12 of lens 10, and the hardening applied to the concave surfacewill be come concave hard coating 24. This produces a finished lens 10.In one embodiment, a lens-cutting machine or a CNC machine is used toform a variety of lens shapes. In another embodiment, two lenses 10 aremounted in a frame to form polarized eyeglasses or spectacles. In yetother embodiments, lens 10 is mounted or combined with other lenses toprovide wrap-around spectacles or masks, single-lens glasses, rimlesseyeglasses, magnifying glasses, telescopes, binoculars, or otherpolarized optical components.

Although the present invention has been described by way of example withreferences to the drawings, it is to be noted herein that variouschanges and modifications, including performing steps in differentorders, will be apparent to those skilled in the art. Therefore, unlesssuch changes and modifications depart from the scope of the presentinvention, they should be construed as being included therein.

Although the present invention has been described by way of example withreferences to the drawings, it is to be noted herein that variouschanges and modifications, including performing steps in differentorders, will be apparent to those skilled in the art. Therefore, unlesssuch changes and modifications depart from the scope of the presentinvention, they should be construed as being included therein.

7. Example 1

FIG. 9 disclose a cross-sectional view of a layered lens produced by theclaimed methods where the convex surface of the first hard coating 204is the surface furthest away from the eyes of the wearer and the concavesurface of the second hard coating 209 is the surface closest surface tothe eyes of the wearer. In one embodiment of the present invention, asdisclosed in FIG. 9 of the present application, the method of making apolarized lens having the steps of:

1. Progressively wetting, stretching, dyeing, cleaning a first polyvinylalcohol (PVA) film 201 by an assembly line having rollers so as to letmolecules of the first PVA film have a parallel lineal direction;

dipped the first polyvinyl alcohol (PVA) film 201 in high contrast dye;

providing a first holder having a lower frame and an upper frame coupledby a hinge;

clipping the first PVA film 201 with a first surface thereof downward inthe first holder, so that both of the upper frame and the lower framewith two opposite plates clip the first PVA film 201 along a directionperpendicular to the parallel direction of molecules in order to preventthe first PVA film 201 itself from shrinking;pressing a first convex mold against the first surface of the first PVAfilm 201 through an opening of the lower frame of the holder, therebysubstantially conforming the first PVA film 201 to the first convexmold, and the first surface becoming a concave surface and a secondsurface opposite the first surface becoming a convex surface;pressing a concave mold against the second surface of the first PVA film201, thereby substantially conforming the first PVA film 201 to theconcave mold;drying the first PVA film 201; remove the first convex mold;progressively wetting, stretching, dyeing, cleaning a second polyvinylalcohol (PVA) film 218 by an assembly line having rollers so as to letmolecules of the second PVA film 218 have a parallel lineal direction;providing a second holder having a lower frame and an upper framecoupled by a hinge; clipping the second PVA film 218 with a firstsurface thereof downward in the second holder, so that both of the upperframe and the lower frame with two opposite plates clip the second PVAfilm 218 along a direction perpendicular to the parallel direction ofmolecules in order to prevent the second PVA film 218 itself fromshrinking; pressing a second convex mold against the first surface ofthe second PVA film 218 through an opening of the lower frame of theholder, thereby substantially conforming the second PVA film 218 to thesecond convex mold, and the first surface becoming a concave surface anda second surface opposite the first surface becoming a convex surface;drying the second PVA film 218. In one embodiment, the second PVA film218 is dipped into a dye tank to add gradient tinting. In anotherembodiment, the second PVA film 218 is dipped into a dye tank to addsolid tinting. In another embodiment, the second PVA film 218 is dippedinto a dye tank to add gradient tinting with the holder and the convexmold holding the PVA film where after the second PVA film 218 havesubstantially conformed to the convex mold and the second PVA film 218have been stabilized and trimmed to conform to the mold; one method ofadding gradient tinting to the PVA film is by dipping it into a dye tankby lowering the holder with the PVA film into the dye tank with dyeingliquid at a first predetermined speed in order to immerse the PVA filmwith a dyeing liquid and then lifting the holder with the PVA film at asecond predetermined speed away from the dyeing liquid in a way that thePVA film is possessed with gradient color. Next applies a quantity ofglue 217 on the center of the first surface of the first PVA film 201;up-side down pressing the second convex mold having the second surfaceof the second PVA film 218 against the glue 217 so as to form alaminated PVA film 230 by spreading the glue 217 in a circular motion;hardening the laminated PVA film 230; and removing the concave mold.

2. Apply a quantity of first epoxy on the center of an upper surface ofa concave mold; up-side down pressing the convex mold having the convexsurface of the laminated PVA film 230 against the first epoxy so as toform a laminated first epoxy film 203 by spreading the first epoxy in acircular motion; hardening the laminated first epoxy film 203; andremoving the concave mold and the second convex mold.

3. Combining a first layer of hard coating 204 to the convex surface ofthe laminated first epoxy film 203.

4. Applying a quantity of second epoxy on a center of the first surfaceof the PVA film 201; pressing the convex mold against the PVA film 201so as to form a laminated second epoxy film 205; hardening the laminatedsecond epoxy film 205.

5. Combining a base material to the concave surface of the laminatedsecond epoxy film 205 to form a polarized lens base unit 206. In oneembodiment, the base material is combined with the laminated secondepoxy film 205 using glue or cell casting or insert injection molding207. In one other embodiment, the base material further comprises gluedpre-formed anti-fog layer 208. Anti-fog layer can be comprised of anymaterial that is suitable for the purpose of preventing fog build up.

6. Combining a second layer of hard coating 209 to the concave surfaceof the polarized lens base unit 206. This example, specifically, withlaminating epoxy coding, laminated PVA films where one PVA film is codedwith high contrast dye, yields surprisingly effective lens that boost acolor differentiation scheme that was effective in blocking out sun raysbased on a high contrast color differentiation scheme.

8. Example 2

FIG. 10 disclose a cross-sectional view of a layered lens produced bythe claimed methods where the convex surface of the first hard coating204 is the surface furthest away from the eyes of the wearer and theconcave surface of the second hard coating 209 is the surface closestsurface to the eyes of the wearer. In one embodiment of the presentinvention, as disclosed in FIG. 10 of the present application, themethod of making a polarized lens having the steps of:

1. progressively wetting, stretching, dyeing, cleaning a first polyvinylalcohol (PVA) film 201 by an assembly line having rollers so as to letmolecules of the first PVA film have a parallel lineal direction; dippedthe first polyvinyl alcohol (PVA) film 201 in high contrast dye;providing a first holder having a lower frame and an upper frame coupledby a hinge; clipping the first PVA film 201 with a first surface thereofdownward in the first holder, so that both of the upper frame and thelower frame with two opposite plates clip the first PVA film 201 along adirection perpendicular to the parallel direction of molecules in orderto prevent the first PVA film 201 itself from shrinking; pressing afirst convex mold against the first surface of the first PVA film 201through an opening of the lower frame of the holder, therebysubstantially conforming the first PVA film 201 to the first convexmold, and the first surface becoming a concave surface and a secondsurface opposite the first surface becoming a convex surface; pressing aconcave mold against the second surface of the first PVA film 201,thereby substantially conforming the first PVA film 201 to the concavemold; drying the first PVA film 201; remove the first convex mold;progressively wetting, stretching, dyeing, cleaning a second polyvinylalcohol (PVA) film 218 by an assembly line having rollers so as to letmolecules of the second PVA film 218 have a parallel lineal direction;providing a second holder having a lower frame and an upper framecoupled by a hinge; clipping the second PVA film 218 with a firstsurface thereof downward in the second holder, so that both of the upperframe and the lower frame with two opposite plates clip the second PVAfilm 218 along a direction perpendicular to the parallel direction ofmolecules in order to prevent the second PVA film 218 itself fromshrinking; pressing a second convex mold against the first surface ofthe second PVA film 218 through an opening of the lower frame of theholder, thereby substantially conforming the second PVA film 218 to thesecond convex mold, and the first surface becoming a concave surface anda second surface opposite the first surface becoming a convex surface;drying the second PVA film 218. In one embodiment, the second PVA film218 is dipped into a dye tank to add gradient tinting. In anotherembodiment, the second PVA film 218 is dipped into a dye tank to addsolid tinting. In another embodiment, the second PVA film 218 is dippedinto a dye tank to add gradient tinting with the holder and the convexmold holding the PVA film where after the second PVA film 218 havesubstantially conformed to the convex mold and the second PVA film 218have been stabilized and trimmed to conform to the mold; one method ofadding gradient tinting to the PVA film is by dipping it into a dye tankby lowering the holder with the PVA film into the dye tank with dyeingliquid at a first predetermined speed in order to immerse the PVA filmwith a dyeing liquid and then lifting the holder with the PVA film at asecond predetermined speed away from the dyeing liquid in a way that thePVA film is possessed with gradient color. Next applies a quantity ofglue 217 on the center of the first surface of the first PVA film 201;up-side down pressing the second convex mold having the second surfaceof the second PVA film 218 against the glue 217 so as to form alaminated PVA film 230 by spreading the glue 217 in a circular motion;hardening the laminated PVA film 230; and removing the concave mold.

2. Apply a quantity of first polyurethane (PU) mixture on the center ofan upper surface of a concave mold; up-side down pressing the convexmold having the convex surface of the laminated PVA film 230 against thefirst PU mixture so as to form a laminated first PU film 202 byspreading the first PU mixture in a circular motion; hardening thelaminated first PU film 202; and removing the concave mold. The first PUmixture is comprised of PU composition with or without IR powder. Theconvex surface of the first PU film 202 can be coated with multi-layervacuum coating.

3. Apply a quantity of first epoxy on the center of an upper surface ofa concave mold; up-side down pressing the convex mold having the convexsurface of the laminated first PU film 202 against the first epoxy so asto form a laminated first epoxy film 203 by spreading the first epoxy ina circular motion; hardening the laminated first epoxy film 203; andremoving the concave mold and the second convex mold.

4. Combining a first layer of hard coating 204 to the convex surface ofthe laminated first epoxy film 203.

5. Applying a quantity of second epoxy on a center of the first surfaceof the PVA film 201; pressing the convex mold against the PVA film 201so as to form a laminated second epoxy film 205; hardening the laminatedsecond epoxy film 205.

6. Combining a base material to the concave surface of the laminatedsecond epoxy film 205 to form a polarized lens base unit 206. In oneembodiment, the base material is combined with the laminated secondepoxy film 205 using glue or cell casting or insert injection molding207. In one other embodiment, the base material further comprises gluedpre-formed anti-fog layer 208. Anti-fog layer can be comprised of anymaterial that is suitable for the purpose of preventing fog build up.

7. Combining a second layer of hard coating 209 to the concave surfaceof the polarized lens base unit 206.

8. Example 3

FIG. 11 disclose a cross-sectional view of a layered lens produced bythe claimed methods where the convex surface of the first hard coating204 is the surface furthest away from the eyes of the wearer and theconcave surface of the second hard coating 209 is the surface closestsurface to the eyes of the wearer. In one embodiment of the presentinvention, as disclosed in FIG. 11 of the present application, themethod of making a polarized lens having the steps of:

1. Progressively wetting, stretching, dyeing, cleaning a first polyvinylalcohol (PVA) film 201 by an assembly line having rollers so as to letmolecules of the first PVA film have a parallel lineal direction;

dipped the first polyvinyl alcohol (PVA) film 201 in high contrast dye;

providing a first holder having a lower frame and an upper frame coupledby a hinge;

clipping the first PVA film 201 with a first surface thereof downward inthe first holder, so that both of the upper frame and the lower framewith two opposite plates clip the first PVA film 201 along a directionperpendicular to the parallel direction of molecules in order to preventthe first PVA film 201 itself from shrinking;pressing a first convex mold against the first surface of the first PVAfilm 201 through an opening of the lower frame of the holder, therebysubstantially conforming the first PVA film 201 to the first convexmold, and the first surface becoming a concave surface and a secondsurface opposite the first surface becoming a convex surface;pressing a concave mold against the second surface of the first PVA film201, thereby substantially conforming the first PVA film 201 to theconcave mold;drying the first PVA film 201; remove the first convex mold;progressively wetting, stretching, dyeing, cleaning a second polyvinylalcohol (PVA) film 218 by an assembly line having rollers so as to letmolecules of the second PVA film 218 have a parallel lineal direction;providing a second holder having a lower frame and an upper framecoupled by a hinge; clipping the second PVA film 218 with a firstsurface thereof downward in the second holder, so that both of the upperframe and the lower frame with two opposite plates clip the second PVAfilm 218 along a direction perpendicular to the parallel direction ofmolecules in order to prevent the second PVA film 218 itself fromshrinking; pressing a second convex mold against the first surface ofthe second PVA film 218 through an opening of the lower frame of theholder, thereby substantially conforming the second PVA film 218 to thesecond convex mold, and the first surface becoming a concave surface anda second surface opposite the first surface becoming a convex surface;drying the second PVA film 218. In one embodiment, the second PVA film218 is dipped into a dye tank to add gradient tinting. In anotherembodiment, the second PVA film 218 is dipped into a dye tank to addsolid tinting. In another embodiment, the second PVA film 218 is dippedinto a dye tank to add gradient tinting with the holder and the convexmold holding the PVA film where after the second PVA film 218 havesubstantially conformed to the convex mold and the second PVA film 218have been stabilized and trimmed to conform to the mold; one method ofadding gradient tinting to the PVA film is by dipping it into a dye tankby lowering the holder with the PVA film into the dye tank with dyeingliquid at a first predetermined speed in order to immerse the PVA filmwith a dyeing liquid and then lifting the holder with the PVA film at asecond predetermined speed away from the dyeing liquid in a way that thePVA film is possessed with gradient color. Next is to apply a quantityof glue 217 on the center of the first surface of the first PVA film201; up-side down pressing the second convex mold having the secondsurface of the second PVA film 218 against the glue 217 so as to form alaminated PVA film 230 by spreading the glue 217 in a circular motion;hardening the laminated PVA film 230; and removing the concave mold.

2. Apply a quantity of first polyurethane (PU) mixture on the center ofan upper surface of a concave mold; up-side down pressing the convexmold having the convex surface of the laminated PVA film 230 against thefirst PU mixture so as to form a laminated first PU film 202 byspreading the first PU mixture in a circular motion; hardening thelaminated first PU film 202; and removing the concave mold.

3. Apply a quantity of second polyurethane (PU) mixture on the center ofan upper surface of a concave mold; up-side down pressing the convexmold having the convex surface of the laminated first PU film 202against the second PU mixture so as to form a laminated secondary PUfilm 210 by spreading the second PU mixture in a circular motion;hardening the laminated secondary PU film 210; and removing the concavemold.

4. Apply a quantity of first epoxy on the center of an upper surface ofa concave mold; up-side down pressing the convex mold having the convexsurface of the laminated secondary PU film 210 against the first epoxyso as to form a laminated first epoxy film 203 by spreading the firstepoxy in a circular motion; hardening the laminated first epoxy film203; and removing the concave mold and the second convex mold.

5. Combining a first layer of hard coating 204 to the convex surface ofthe laminated first epoxy film 203.

6. Applying a quantity of second epoxy on a center of the first surfaceof the PVA film 201; pressing the convex mold against the PVA film 201so as to form a laminated second epoxy film 205; hardening the laminatedsecond epoxy film 205.

7. Combining a base material to the concave surface of the laminatedsecond epoxy film 205 to form a polarized lens base unit 206. In oneembodiment, the base material is combined with the laminated secondepoxy film 205 using glue or cell casting or insert injection molding207. In one other embodiment, the base material further comprises gluedpre-formed anti-fog layer 208. Anti-fog layer can be comprised of anymaterial that is suitable for the purpose of preventing fog build up.

8. Combining a second layer of hard coating 209 to the concave surfaceof the polarized lens base unit 206.

9. Example 4

FIG. 12 disclose a cross-sectional view of a layered lens produced bythe claimed methods where the convex surface of the camouflagedpatterned lens is the surface furthest away from the eyes of the wearerand the concave surface of the second hard coating 209 is the surfaceclosest surface to the eyes of the wearer. In one embodiment of thepresent invention, as disclosed in FIG. 12 of the present application,the method of making a polarized lens having the steps of:

1. Progressively wetting, stretching, dyeing, cleaning a first polyvinylalcohol (PVA) film 201 by an assembly line having rollers so as to letmolecules of the first PVA film have a parallel lineal direction; dippedthe first polyvinyl alcohol (PVA) film 201 in high contrast dye;providing a first holder having a lower frame and an upper frame coupledby a hinge; clipping the first PVA film 201 with a first surface thereofdownward in the first holder, so that both of the upper frame and thelower frame with two opposite plates clip the first PVA film 201 along adirection perpendicular to the parallel direction of molecules in orderto prevent the first PVA film 201 itself from shrinking;

pressing a first convex mold against the first surface of the first PVAfilm 201 through an opening of the lower frame of the holder, therebysubstantially conforming the first PVA film 201 to the first convexmold, and the first surface becoming a concave surface and a secondsurface opposite the first surface becoming a convex surface;pressing a concave mold against the second surface of the first PVA film201, thereby substantially conforming the first PVA film 201 to theconcave mold;drying the first PVA film 201; remove the first convex mold;progressively wetting, stretching, dyeing, cleaning a second polyvinylalcohol (PVA) film 218 by an assembly line having rollers so as to letmolecules of the second PVA film 218 have a parallel lineal direction;providing a second holder having a lower frame and an upper framecoupled by a hinge; clipping the second PVA film 218 with a firstsurface thereof downward in the second holder, so that both of the upperframe and the lower frame with two opposite plates clip the second PVAfilm 218 along a direction perpendicular to the parallel direction ofmolecules in order to prevent the second PVA film 218 itself fromshrinking; pressing a second convex mold against the first surface ofthe second PVA film 218 through an opening of the lower frame of theholder, thereby substantially conforming the second PVA film 218 to thesecond convex mold, and the first surface becoming a concave surface anda second surface opposite the first surface becoming a convex surface;drying the second PVA film 218. In one embodiment, the second PVA film218 is dipped into a dye tank to add gradient tinting. In anotherembodiment, the second PVA film 218 is dipped into a dye tank to addsolid tinting. In another embodiment, the second PVA film 218 is dippedinto a dye tank to add gradient tinting with the holder and the convexmold holding the PVA film where after the second PVA film 218 havesubstantially conformed to the convex mold and the second PVA film 218have been stabilized and trimmed to conform to the mold; applying aquantity of glue 217 on the center of the first surface of the first PVAfilm 201; up-side down pressing the second convex mold having the secondsurface of the second PVA film 218 against the glue 217 so as to form alaminated PVA film 230 by spreading the glue 217 in a circular motion;hardening the laminated PVA film 230; and removing the concave mold.

2. Apply a quantity of first polyurethane (PU) mixture on the center ofan upper surface of a concave mold; up-side down pressing the convexmold having the convex surface of the laminated PVA film 230 against thefirst PU mixture so as to form a laminated first PU film 202 byspreading the first PU mixture in a circular motion; hardening thelaminated first PU film 202; and removing the concave mold. The first PUmixture is comprised of PU composition mixed with Photochromic powder.The PU mixture can further incorporate IR powder.

3. Apply a quantity of epoxy mixture on the center of an upper surfaceof a concave mold; up-side down pressing the convex mold having theconvex surface of the laminated first PU film 202 against the firstepoxy mixture so as to form a laminated epoxy mixture film 216 byspreading the epoxy mixture in a circular motion; hardening thelaminated epoxy mixture film 216; and removing the concave mold and thesecond convex mold.

4. Next is to apply a camouflaged patterned lens 212 by gluing it to theconvex surface of the laminated epoxy mixture film 216. The camouflagedpatterned lens 212 is made comprising the following steps: a. providinga lens having a convex surface and a concave surface; b. combining alayer of hard coating to the convex surface of the lens; c. plasmatreating at least one lens surface, the lens having inner and outersurfaces as well as sides; d. applying a removable ink layer onto theplasma treated lens surface, the removable ink layer forming clear andshaded areas on the lens surface; e. applying a base ink layer over theremovable ink layer, the base ink layer at least partially filling theclear areas formed on the lens surface; f. applying at least one coloredink layer over the base ink layer; and f. removing the removable inklayer. The lens can be a plastic lens whereby the materials can beeither polycarbonate, tri-acetyl cellulose (TAC), cellulose acetatebutyrate (CAB), polyurethane (PU), nylon or polyethylene terephthalate(PET). The method of making camouflaged patterned lens is furtherdisclosed in the United States patent published application no.20080151182 titled “Layered lenses and method of layering lenses” by theHsu; Roger Wen-Yi. The disclosures of which are incorporated herein byreference.

The method of making camouflaged patterned lens is further disclosed inthe United States patent published application no. 20080151182 titled“Layered lenses and method of layering lenses” by the Hsu; Roger Wen-Yi.The disclosures of which are incorporated herein by reference.

5. Applying a quantity of second epoxy on a center of the first surfaceof the PVA film 201; pressing the convex mold against the PVA film 201so as to form a laminated second epoxy film 205; hardening the laminatedsecond epoxy film 205.

6. Combining a base material to the concave surface of the laminatedsecond epoxy film 205 to form a polarized lens base unit 206. In oneembodiment, the base material is combined with the laminated secondepoxy film 205 using glue or cell casting or insert injection molding207. In one other embodiment, the base material further comprises gluedpre-formed anti-fog layer 208. Anti-fog layer can be comprised of anymaterial that is suitable for the purpose of preventing fog build up.

7. Combining a second layer of hard coating 209 to the concave surfaceof the polarized lens base unit 206.

10. Example 5

FIG. 13 disclose a cross-sectional view of a layered lens produced bythe claimed methods where the convex surface of the camouflagedpatterned lens 212 is the surface furthest away from the eyes of thewearer and the concave surface of the second hard coating 209 is thesurface closest surface to the eyes of the wearer. In one embodiment ofthe present invention, as disclosed in FIG. 13 of the presentapplication, the method of making a polarized lens having the steps of:

1. Progressively wetting, stretching, dyeing, cleaning a first polyvinylalcohol (PVA) film 201 by an assembly line having rollers so as to letmolecules of the first PVA film have a parallel lineal direction; dippedthe first polyvinyl alcohol (PVA) film 201 in high contrast dye;providing a first holder having a lower frame and an upper frame coupledby a hinge; clipping the first PVA film 201 with a first surface thereofdownward in the first holder, so that both of the upper frame and thelower frame with two opposite plates clip the first PVA film 201 along adirection perpendicular to the parallel direction of molecules in orderto prevent the first PVA film 201 itself from shrinking;

pressing a first convex mold against the first surface of the first PVAfilm 201 through an opening of the lower frame of the holder, therebysubstantially conforming the first PVA film 201 to the first convexmold, and the first surface becoming a concave surface and a secondsurface opposite the first surface becoming a convex surface;pressing a concave mold against the second surface of the first PVA film201, thereby substantially conforming the first PVA film 201 to theconcave mold;drying the first PVA film 201; remove the first convex mold;progressively wetting, stretching, dyeing, cleaning a second polyvinylalcohol (PVA) film 218 by an assembly line having rollers so as to letmolecules of the second PVA film 218 have a parallel lineal direction;providing a second holder having a lower frame and an upper framecoupled by a hinge; clipping the second PVA film 218 with a firstsurface thereof downward in the second holder, so that both of the upperframe and the lower frame with two opposite plates clip the second PVAfilm 218 along a direction perpendicular to the parallel direction ofmolecules in order to prevent the second PVA film 218 itself fromshrinking; pressing a second convex mold against the first surface ofthe second PVA film 218 through an opening of the lower frame of theholder, thereby substantially conforming the second PVA film 218 to thesecond convex mold, and the first surface becoming a concave surface anda second surface opposite the first surface becoming a convex surface;drying the second PVA film 218. In one embodiment, the second PVA film218 is dipped into a dye tank to add gradient tinting. In anotherembodiment, the second PVA film 218 is dipped into a dye tank to addsolid tinting. In another embodiment, the second PVA film 218 is dippedinto a dye tank to add gradient tinting with the holder and the convexmold holding the PVA film where after the second PVA film 218 havesubstantially conformed to the convex mold and the second PVA film 218have been stabilized and trimmed to conform to the mold;applying a quantity of glue 217 on the center of the first surface ofthe first PVA film 201; up-side down pressing the second convex moldhaving the second surface of the second PVA film 218 against the glue217 so as to form a laminated PVA film 230 by spreading the glue 217 ina circular motion; hardening the laminated PVA film 230; and removingthe concave mold.

2. Apply a quantity of epoxy mixture on the center of an upper surfaceof a concave mold; up-side down pressing the convex mold having theconvex surface of the laminated PVA film 230 against the epoxy mixtureso as to form a epoxy mixture film 216 by spreading the epoxy mixture ina circular motion; hardening the laminated epoxy mixture film 202; andremoving the concave mold. The epoxy mixture is comprised of epoxy withor without IR powder. The convex surface of the laminated epoxy mixturefilm 202 can be coated with multi-layer vacuum coating.

3. Next is to apply a camouflaged patterned lens 212 by gluing it to theconvex surface of the laminated epoxy mixture film 216. The camouflagedpatterned lens 212 is made comprising the following steps: a. providinga lens having a convex surface and a concave surface; b. combining alayer of hard coating to the convex surface of the lens; c. plasmatreating at least one lens surface, the lens having inner and outersurfaces as well as sides; d. applying a removable ink layer onto theplasma treated lens surface, the removable ink layer forming clear andshaded areas on the lens surface; e. applying a base ink layer over theremovable ink layer, the base ink layer at least partially filling theclear areas formed on the lens surface; f. applying at least one coloredink layer over the base ink layer; and f. removing the removable inklayer. The lens can be a plastic lens whereby the materials can beeither polycarbonate, tri-acetyl cellulose (TAC), cellulose acetatebutyrate (CAB), polyurethane (PU), nylon or polyethylene terephthalate(PET). The color of the colored ink layer can be opaque. The method ofmaking camouflaged patterned lens is further disclosed in the UnitedStates patent published application no. 20080151182 titled “Layeredlenses and method of layering lenses” by the Hsu; Roger Wen-Yi. Thedisclosures of which are incorporated herein by reference.

4. Applying a quantity of second epoxy on a center of the first surfaceof the PVA film 201; pressing the convex mold against the PVA film 201so as to form a laminated second epoxy film 205; hardening the laminatedsecond epoxy film 205.

5. Combining a base material to the concave surface of the laminatedsecond epoxy film 205 to form a polarized lens base unit 206. In oneembodiment, the base material is combined with the laminated secondepoxy film 205 using glue or cell casting or insert injection molding207. In one other embodiment, the base material further comprises gluedpre-formed anti-fog layer 208. Anti-fog layer can be comprised of anymaterial that is suitable for the purpose of preventing fog build up.

6. Combining a second layer of hard coating 209 to the concave surfaceof the polarized lens base unit 206. This example, specifically, withlaminating epoxy coding, laminated PVA films where one PVA film is codedwith high contrast dye, and with camouflaged patterned lens, yieldssurprisingly effective lens that boost a color differentiation schemethat was effective in blocking out sun rays based on a high contrastcolor differentiation scheme and yet that is effective in a camouflagedscheme for hunting or for military uses.

Example 6

FIG. 14 depicts a method wherein the first PVA film 112 is dipped in atank 156 containing color of choice wherein the first PVA film 112 isclipped by a frame 114. The figure further discloses method of rotatingthe frame 114 slowly and continuously in the tank 156.

1. A method of making a polarized lens comprising the steps of:progressively wetting, stretching, dyeing, and cleaning a firstpolyvinyl alcohol (PVA) film by an assembly line having rollers so as tolet molecules of the first PVA film have a parallel linear direction;providing a first holder having a lower frame and an upper frame coupledby a hinge; clipping the first PVA film by having the upper frame closedonto the lower frame wherein a first surface of the PVA film faces thelower frame and a second surface of the PVA film faces the upper frameso that both of the upper frame and the lower frame with two oppositeplates clip the first PVA film along a direction perpendicular to theparallel direction of molecules in order to prevent the first PVA filmitself from shrinking; pressing a first convex mold against the firstsurface of the first PVA film through an opening of the lower frame ofthe holder, thereby substantially conforming the first PVA film to thefirst convex mold, and the first surface becoming a concave surface anda second surface opposite the first surface becoming a convex surface;pressing a concave mold against the second surface of the first PVAfilm, thereby substantially conforming the first PVA film to the concavemold; drying the first PVA film; remove the first convex mold;progressively wetting, stretching, dyeing, cleaning a second polyvinylalcohol (PVA) film by an assembly line having rollers so as to letmolecules of the second PVA film have a parallel lineal direction;providing a second holder having a lower frame and an upper framecoupled by a hinge; clipping the second PVA film with a first surfacethereof downward in the second holder, so that both of the upper frameand the lower frame with two opposite plates clip the second PVA filmalong a direction perpendicular to the parallel direction of moleculesin order to prevent the second PVA film itself from shrinking; pressinga second convex mold against the first surface of the second PVA filmthrough an opening of the lower frame of the holder, therebysubstantially conforming the second PVA film to the second convex mold,and the first surface becoming a concave surface and a second surfaceopposite the first surface becoming a convex surface; drying the secondPVA film; applying a quantity of glue on the center of the first surfaceof the first PVA film; up-side down pressing the second convex moldhaving the second surface of the second PVA film against the glue so asto form a laminated PVA film by spreading the glue in a circular motion;hardening the laminated PVA film; and removing the concave mold.
 2. Amethod of making a polarized lens comprising the steps of: progressivelywetting, stretching, dyeing, and cleaning a first polyvinyl alcohol(PVA) film by an assembly line having rollers so as to let molecules ofthe first PVA film have a parallel linear direction; providing a firstholder having a lower frame and an upper frame coupled by a hinge;clipping the first PVA film with a first surface thereof downward in theholder, so that both of the upper frame and the lower frame with twoopposite plates clip the first PVA film along a direction perpendicularto the parallel direction of molecules in order to prevent the first PVAfilm itself from shrinking; pressing a first convex mold against thefirst surface of the first PVA film through an opening of the lowerframe of the holder, thereby substantially conforming the first PVA filmto the first convex mold, and the first surface becoming a concavesurface and a second surface opposite the first surface becoming aconvex surface; pressing a concave mold against the second surface ofthe first PVA film, thereby substantially conforming the first PVA filmto the concave mold; drying the first PVA film; remove the first convexmold; progressively wetting, stretching, dyeing, cleaning a secondpolyvinyl alcohol (PVA) film by an assembly line having rollers so as tolet molecules of the second PVA film have a parallel lineal direction;providing a second holder having a lower frame and an upper framecoupled by a hinge; clipping the second PVA film with a first surfacethereof downward in the second holder, so that both of the upper frameand the lower frame with two opposite plates clip the second PVA filmalong a direction perpendicular to the parallel direction of moleculesin order to prevent the second PVA film itself from shrinking; pressinga second convex mold against the first surface of the second PVA filmthrough an opening of the lower frame of the holder, therebysubstantially conforming the second PVA film to the second convex mold,and the first surface becoming a concave surface and a second surfaceopposite the first surface becoming a convex surface; drying the secondPVA film; applying a quantity of glue on the center of the first surfaceof the first PVA film; up-side down pressing the second convex moldhaving the second surface of the second PVA film against the glue so asto form a laminated PVA film by spreading the glue in a circular motion;hardening the laminated PVA film; and removing the concave mold;applying a quantity of first epoxy on the center of an upper surface ofthe concave mold; up-side down pressing the second convex mold havingthe convex surface of the laminated PVA film against the first epoxy soas to form a laminated first epoxy film by spreading the first epoxy ina circular motion; hardening the laminated first epoxy film; andremoving the concave mold.
 3. The method of claim 1 further comprisingapplying a quantity of first polyurethane (PU) mixture on the center ofan upper surface of the concave mold; up-side down pressing the secondconvex mold having the second surface of the laminated PVA film againstthe first PU mixture so as to form a laminated first PU film byspreading the first PU mixture in a circular motion; hardening thelaminated first PU film; and removing the concave mold.
 4. The method ofclaim 3 further comprising applying a quantity of first epoxy on thecenter of an upper surface of the concave mold; up-side down pressingthe second convex mold having the convex surface of the laminated firstPU film against the first epoxy so as to form a laminated first epoxyfilm by spreading the first epoxy in a circular motion; hardening thelaminated first epoxy film; and removing the concave mold.
 5. The methodof claim 3 further comprising applying a quantity of second PU mixtureon the center of an upper surface of the concave mold; up-side downpressing the second convex mold having the convex surface of the firstPU film against the second PU mixture so as to form a laminated secondPU film by spreading the second PU mixture in a circular motion;hardening the laminated secondary PU film, and removing the concavemold.
 6. The method of claim 5 further comprising applying a quantity offirst epoxy on the center of an upper surface of the concave mold;up-side down pressing the convex mold having the convex surface of thesecondary film against the first epoxy so as to form a laminated firstepoxy film by spreading the first epoxy in a circular motion; hardeningthe laminated first epoxy film, and removing the concave mold.
 7. Themethod of claim 3 further comprising applying a quantity of epoxymixture on the center of an upper surface of the concave mold; up-sidedown pressing the convex mold having the convex surface of the laminatedfirst PU film against the epoxy mixture so as to form a laminated epoxymixture film by spreading the epoxy mixture in a circular motion;hardening the laminated epoxy mixture film, and removing the concavemold and the convex mold.
 8. The method of claim 7 wherein a camouflagedpatterned lens is glued to the convex surface of the laminated epoxymixture film.
 9. The method of claim 1 further comprising applying aquantity of epoxy mixture on the center of an upper surface of theconcave mold; up-side down pressing the convex mold having the convexsurface of the laminated PVA film against the epoxy mixture so as toform a laminated epoxy mixture film by spreading the epoxy mixture in acircular motion; hardening the laminated epoxy mixture film, andremoving the concave mold and the convex mold.
 10. The method of claim 9wherein a camouflaged patterned lens is glued to the convex surface ofthe laminated epoxy mixture film.
 11. The method of claim 2, 4 or 6further comprises combining a first layer of hard coating to the convexsurface of the laminated first epoxy film.
 12. The method of claim 8 or10 further comprises combining a first layer of hard coating to theconvex surface of the camouflaged patterned lens.
 13. The method ofclaim 1, wherein the step of progressively wetting, stretching, dyeing,cleaning the first and second PVA film, comprising the steps ofproviding a roll of PVA film; providing an assembly line having rollers;mounting the roll of PVA film at the beginning of the assembly line;using water to wet the PVA film at a first stage of the assembly lineuntil it has moisture content between 70% and 85%; stretching the PVAfilm at a second stage of the assembly line; and dye-dipping the PVAfilm at a third stage of the assembly line until the PVA filmsubstantially polarized.
 14. The method of claim 13, wherein each stagehaving at least one bath and each bath having rollers placed at a lowerposition closed to the bottom and rollers placed at a higher positionand from a bath to another also having rollers placed atop sidewallsbetween two adjacent baths so that the PVA film can be stretchedcontinuously.
 15. The method of claim 1, after the step of clipping thePVA film with a first surface thereof downward in the holder and beforethe steps of pressing a convex mold against the first surface of the PVAfilm further comprises the steps of: stabilizing the PVA film; andcutting the PVA film.
 16. The method of claim 1, wherein the step ofprogressively wetting, stretching, dyeing, cleaning the second PVA filmby an assembly line comprises: dipping the second PVA film to addgradient tinting.
 17. The method of claim 1 or 13, wherein the step ofprogressively wetting, stretching, dyeing, cleaning the second PVA filmby an assembly line comprises: dipping the second PVA film to add solidtinting.
 18. The method of claim 3, wherein the first polyurethanemixture is comprised of polyurethane composition and Photochromicpowder.
 19. The method of claim 3, wherein the first polyurethanemixture is comprised of polyurethane composition.
 20. The method ofclaim 19 wherein the convex surface of the laminated first PU film iscoated with multi-layer vacuum coating.
 21. The method of claim 5wherein the second polyurethane mixture is comprised of a polyurethanecomposition mixed with hindered amine stabilizer.
 22. The method ofclaim 21 wherein the convex surface of the laminated secondary PU filmis coated with multi-layer vacuum coating.
 23. The method of claim 8 or10 wherein the camouflaged patterned lens is made comprising thefollowing steps: providing a lens having a convex surface and a concavesurface; combining a layer of hard coating to the convex surface of thelens; plasma treating at least one lens surface, the lens having innerand outer surfaces as well as sides; applying a removable ink layer ontothe plasma treated lens surface, the removable ink layer forming clearand shaded areas on the lens surface; applying a base ink layer over theremovable ink layer, the base ink layer at least partially filling theclear areas formed on the lens surface; applying at least one coloredink layer over the base ink layer; and removing the removable ink layer.24. The method of claim 23, wherein the lens comprises a plastic lens.25. The method of claim 24, wherein the plastic lens comprises amaterial selected from the group consisting of: polycarbonate,tri-acetyl cellulose (TAC), cellulose acetate butyrate (CAB),polyurethane (PU), nylon and polyethylene terephthalate (PET).
 26. Themethod of claim 7 wherein the epoxy mixture comprises a quantity ofepoxy and a quantity of hindered amine stabilizer.
 27. The method ofclaim 26 wherein the laminated epoxy mixture film is coated withmulti-layer vacuum coating on the convex surface of the laminated epoxymixture film.
 28. The method of claim 9 wherein the epoxy mixturecomprises a quantity of epoxy.
 29. The method of claim 28 wherein theepoxy mixture further comprises a quantity of hindered amine stabilizer.30. The method of claim 29 wherein the laminated epoxy mixture film iscoated with multi-layer vacuum coating on the convex surface of thelaminated epoxy mixture film.
 31. The method of claim 11 or 12 furthercomprising applying a quantity of second epoxy on a center of the firstsurface of second PVA film; pressing the convex mold against the secondPVA film so as to form a laminated second epoxy film; hardening thelaminated second epoxy film, and removing the convex mold.
 32. Themethod of claim 31 further comprises: combining a base material to theconcave surface of the laminated second epoxy film to form a polarizedlens base unit.
 33. The method of claim 32, wherein the base materialcomprises: at least one material selected from the group ofpolycarbonate, polyurethane, nylon, CR-39, glass, Acrylic.
 34. Themethod of claim 32 wherein the base material is combined with thelaminated second epoxy film using glue or cell casting or insertinjection molding.
 35. The method of claim 32 wherein the base materialfurther comprises glued pre-formed anti-fog layer.
 36. The method ofclaim 32 further comprises combining a second layer of hard coating tothe concave surface of the polarized lens base unit.
 37. The method ofclaim 1 wherein the glue is epoxy or polyurethane.
 38. The method ofclaim 1 wherein the first PVA film is dipped in a tank containing highcontrast dye wherein the first PVA film is clipped by a frame, rotatingthe frame slowly and continuously.
 39. The method of claim 38, whereinthe step of progressively wetting, stretching, dyeing, cleaning a firstPVA film by an assembly line comprises: dipping the first PVA film toadd solid tinting.
 40. The method of 23 wherein the color of the coloredink layer is opaque.
 41. The method of claim 1 further comprises: beforedrying the second PVA film, lower the second holder with the second PVAfilm at a first predetermined speed into a dye tank with dyeing liquid,lifting the holder with the PVA film at a second predetermined speedaway from the dying liquid so the PVA film possesses a gradient color.42. The method of claim 13, wherein the step of progressively wetting,stretching, dyeing, cleaning the second PVA film by an assembly linecomprises: dipping the second PVA film to add gradient tinting.
 43. Themethod of claim 13, wherein the step of progressively wetting,stretching, dyeing, cleaning the second PVA film by an assembly linecomprises: dipping the second PVA film to add solid tinting.
 44. Themethod of claim 3 wherein the convex surface of the laminated first PUfilm is coated with multi-layer vacuum coating.